Head-lamp replacement unit



March 5, 1929. F, A BU KL ET AL 1,704,028

HEADLAiMP REPLACEMENT UNIT Filed Jan. 28, 1924 2 Sheets-Sheet m p w MW M M w i 2/ a u f p Z d y 2 Z 4 8 6 9 w 9 mi 5 l i Z 1 u 5 w I; m 8 H 1 0 MW 1 t 8 8 4 a 8 MM 1 V H M $2 4 L 5 5 f 1 mw 7 3+? .l 3 U 2 ad 7 3 w INVENTOR Samue/ E flrbz/dr/e Carl R Broc/rwag ATTORNEY March 5, 1929. s. F. ARBUCKLE ETAL 1,704,028

HEADLAMP REPLACEMENT UNIT Filed Jan, 28, 1924 2 Sheets-Sheet 2 INVENTOR y ATTORNEY Patented Mar. 5,.1929.

UNITED STATES HEAD-LAMP REPLACEMENT UNIT.

Application filed January 28, 1924. Serial No. 688,947.

This invention relates to'an assembly for headlamps having particular utilization in connection with replacement reflectors for automobile headlamps.

Particularly in connection with an automobile headlamp, the practice has recently for the replacement reflector the lamp either in the is removable from the lamp;

arisen of replacing aworn or inefiicient reflector surface by a second or replacement reflector placed within and supported by the old reflector, thus giving the efi'ect of a new reflecting surface. In applying the second reflector, various means have been employed such as edge flange attaching means which tend to distort the true parabolic curvature of the second reflector and give rise to various difliculties of adjustment.

Among the objectsinvolved in the invention is, therefore, the inclusion of means whereby a secondary or replacement reflector is applied to the old or rimary reflector of the headlamp construction by means of a single assembly unit. object is the employment of an assembly unit which will permit the adjustment of direction of the lam axis or in a plane transverse thereto. It is an important object also, to rovide means which will permit yield 0 the holding mechanism of the replacement reflector in accordance with variations in curvature of the primary reflector or supporting base. Stilt another object involved-is the utilization of a yielding auxiliary support element which, by reversal, may be -utilized for; primary reflectors of different curvature. Various other objects are'comprehended within the scope of the invention, including the provision of means for preventing through the shielding, of, direct rays emer ing from the lamp filament, above a horizontal plane passing approximately through the center of or .just below the lamp filament; the provision of a lamp shield which the provision of a lamp shield which has a definite predetermined relationship with the lamp filament and with the nature of the curvature of the secondary reflector; the utilization of an opaque band, strip or shield toward the tip of the lamp tending to prevent passage of direct rays to that portion of the primary reflector which extends beyond the lower edge of the primary or replacement re- Another important direct glare flector; and various other objects involved in the details of the construction and methods of manufacture which will become ap arent on consideration of the specific embo iment which may be preferred of the invention herein described and illustrated in the ac companying drawing.

eferring to the drawings of the applicat1on:

Fig. 1 shows a sectional elevation of a headlamp adapted to be used on a vehicle in which is inserted a secondary or replacement reflector and showing the various connecting elements entering into the complete assembly;

Fig. 2 is a view of a re unit applicable to an or .flector showing a fabric front of the reflector;

Fig. 3 is a detailed supporting element;

Fig. 4 is a view of a modified construction of the shield showing the application of the same to the bulb of an ordinary reflector; and

Fig. 5 shows a still further modification of the glare preventin shield.

Generally stated, the invention is comprehended in simplified means for connecting a replacement reflector to the ordinary reflector of the headlamp which includes means for rotatably and axially adjusting the lamp within the replacement reflector lacement reflector lnary primary resheet covering in view of the 'auxiliary from a central tubular support insertible within the socket of the old reflector.

A feature of the invention is the provision of a shield adapted to be positioned in front of the lamp so as to cut oil u wardly directed rays, a structure ada ted to prevent glare in t e lamp, particular y when utilized on a moving vehicle, and in such weather conditions where makes it exceedingly diflicult to operate a vehicle, safely.

The invention, While having general applicability to lamps of various designs and uses, is herein shown as applied to an .automobile headlamp of a design including an outer casing 11, and a reflector 12 mounted within the same. As shown, the method of assembly involves the formation of a central aperture 13 in which is positiond a central cylindrical tube 14 adapted to hold a contact tube 15 within the same.

the presence of fog or mist joint connection,

The reflector 12 has a central aperture 16 and an outer'extending. central flange 17 having the same diameter as that of the cylinder 14.- and adapted to be inserted over. the end of the contact cylinder 15, thus forming a unified tubular connection between the reflector and headlamp casing.

The outer edge of the reflector is expanded in a plane perpendicular to the axis thereof to. form a narrow rim annular groove 21 in which is positioned a' yielding cord fabric 22 adapted to contact with the lens 23 of the headlamp. The outer edge of the rim 20 is turned reversely and outwardly toform a contact surface 5 with the inside of the casing 11. Rim plate 24- is rovided having an inner flange turned parallel to the reflector axis and contactin on its end with the lens of the headlamp and an outer flange 26 parallel to the flange 25 and overlapping and adapted to be remov= ably attached to the outer rim of the headlight casing 11. I p

The contact tube 15 holds the electrical contacts, completing the circuit between the outside electrical source to which connection, is made by the cord 29 and lamp bulb 30. The rear end of the tube 15 extends beyond the rear side of the casing 11 and is cut axially and radially-on opposite sidesin L-formation to form-the slots 31 of a bayonet the same being adapted to receive the pins 32, extending radially from the body of the plug 33 at the end of the connecting cord 29. The connecting plug 33 is formed of electrically insulatin material with a central electrical contact p ate 34.

lVithin the tubing plates 35 and 4, and held in position within the tube by 'means'of annular inwardly directed depres;

sions 36 and 3. In the body of the tube, blocks 37 and 2 are attached to the plates 35 and 4 adjacent their centers and through apertures passing through these plates and blocks, pins 38- and 39 are adapted to have axial movement. On adjacent ends of the pins 38 and 39 are formed integral. there with annular flanges 40 and intermediate these plates 4E0 a spring 41 is adapted to exert pressure, tending to hold the pins to the outer limits of their movement, the in 38 against the contact. plate 34- on the p ug 33, and the pin 39 against the movable b ock 56, thus making connection with the base of the lamp 36. V,

The contact cylinder 15 is adapted to have axial'movement within the tube 1% and the reflector tube 17, there being a slot 51. formed axially in the tube 14 through which lug 52, rigidly attached to the cylinder 15, extends. VV ith this lug 52 an adjustment screw' 53 is adapted to have screw-threaded engagement, the end of the screw 5% extending to .the exterior of the casing where it may be manipu may move the tube 15.

casing to sucha point "of adjustment as se-' 20 having a central I 15 arepositioned two formed of dialectric material engagement with a woe-pee lated by the operator. A. coiled string 55 surrounds the shank of the .screw intermediate the casing and the outstanding lug 52, tending to'maintain the cylinder 15 constantly at its innermost limit. It is obvious that by means of the screw 53 the operator axially within the cures the best results desired.

Fig. 2 shows the entire replacement unit adapted to be inserted bodily within the reflector of an ordinary headlamp when either by use or other cause, the original reflector has become relatively valueless as a reflecting medium. As illustrated in this figure, the unit includes a reflector 60, the outer edge'of which terminates in a radially extending ,flange 61 to which is attached a sheet of paper or card-board 62. The purpose of the paper sheet or cardboard 62 is primarily to protect the finely finished refleeting surface of the reflectory unit during transportation from the pointcof manufacture to the distributor or user and also to prevent mal-adjustment of the movable portions of the unit by unauthorized persons. The purchaser of-the unit may be assured if the papersheet is unbroken that the lamp unit is in .the condition in which it was originally assembled and responsibility for any defect in the construction may be readily ascertained. The center of the reflector is cut to form a central aperture 63, in which is adapted to be positioned the shoulder 64: of a holding members 65. The member 65 is positioned upon a tube 66 forming a plug 67 of diminished cross section and a socket 68 of increased cross section, the ends of the socket 68 extending within the reflector as separate yielding arms 69 having outturned ends 7 O. The holding member 65 rests upon these socket ends 69 adjacent to the outturned portions 70. The socket adjacent the junction of the plug 67 is externally screwthreaded'and is adapted to receive a nut' 17 0 in screw-threaded engagement therewith which is designed to be moved into close washer 71, contacting with the central outer edge of the reflector and bind the reflector to the holding member 65. It is a parent that rotation of the nut 170 in a irection to tighten the same 11 on the socket 66 will tend to force the hol ing member inwardly against the inclined end 70 of thesocket arms 69,. this operation, as will appear from the description succeeding, binding the reflector closely to its means of support.

Similarly positioned on the screw-threaded socket is a second nut 72 which is adapted to bind against the first mentioned nut 17 O tl1rougl1 a washer 73. A central portion portion 75 lies in a surface inclined to the against which a strip 0 plane of the central portion 74. The outer portion 7 5 of the washer 73. is split radially to form a plurality of sectors 76 and inasmuch as the material of which-the washer 73 is formed is resilient, it is obvious that the washer forms resilientholding or'supporting means when applied to the reflector in which the unit is to be positioned; This is apparent. from consideration of the unit as assembled in'Fig. 1, the ends of the sectors 76 contacting against the surface of the original or primary reflector 12 of the headlamp, yield'ingly maintaining the tube 60 in proper relationship therewith. The .plug 67 is provided with outstanding, oppositely positioned lugs 80 which are adapted to enter the bayonet slots 131 formed in the ends of the movable contact tube 15, this structure being the usual headlamp construction. The socket 68 is adapted to receive the base of the lamp 30 and hold the same in proper contacting relationship with the replacement reflector 60. In addition to serving as a connecting means between the contact tube 15 and lamp 30, the plug 67 is adapted also to hold by means of a dielectric cylinder 81 a contact rod 82 movable axially theretlinough. The cylindrical block 81 is held in fisition within the plug 67 by a downturndd flange 83 at the end of the plug and a plurality of inwardly directed indenta tions 84 ormed in the plug adjacent the inner end of the block 81. The contact rod 82 is divided into two sections 85 and 86 which are held to each other by means of screw-thread 87. One end of the rod section 85 terminates in a contact late 88 the pin 39 is adapted to have yielding connections and the other end of the rod section 86 similarly is provided with a contact plate 89 adapted to contact with the base of the lamp 30.v It is' observable that the contact rod 82 within the block 81 so'that it may accommodate itself to the relative position of the lamp base and the end of the contact-39 and further that if the lamp base is abnormally fixed relative to the socket of the head lamp by adjusting the two'sections of the a connecting rod 82, a proper amount of sepa ration may be obtained which gives the most eflicient results for the particular headlamp and reflector used.

In Figs. 1 and 2 there is illustrated a novel form of connection intermediate the replacement lamp socket 66 which is combined with means for preventin glare from the reflector. From metal a stamping is made which at its central part is in the shape of a sector 90, this sector forming a shell conforming to the curvature of the lamp bulb 30 and covering a limited'portion thereof, extending from a point somewhat below the axis of the reflectorineluding the filament of the quently, light rays .522 of theshield sector 90, these .Depending from the inner edge of around the lamp bulb so as to join is slidahlypositioncdlamp, to a point, in front of a plane passing transversely through the filament of the lamp and above the axis thereof. The upper houndar of the sector is adapted to lie in a sur rality of lines from the focal point 91of the reflector, at which the filament of the lamp is positioned, to the outer edge of the replacement or secondary reflector 60, or, as indicated in Fig. 1, in a plane transverse to the lamp axis and in front of the filament.

In other words, the-shield 90 is 'of such dimensions that ra s of light emerging at the focus of the re 'ector 60. will be sto ped by the shield 90 from passage to the fi'ont of the reflector above a plane including the base 92 of the shield parallelto a lane passing tothe axis of the reflector. onsewill emer e only as reflected from the surface of tie reflector or such as passout directly beneath the base rays being horizontal any lare headl dmp. the sector direction opposite sides of the sector is a band 93, the same serving both as an auxiliary holding means forretaining the shield 90 in position and also as a shield for preventing the passage of direct raysof the lamp filament to that portion 94 of'the original or primary reflector 12 -which extends beyond the outer edge of the secondary reflector plane 61. The shield 90, is held in position to the lamp bulb by. means of lateral bands 94, 95, which extend toward the base of the lamp and terminate in semi-cylindrical half tubes 96 and 97, the end of the tube adjacent the strap or band 94, having a'greater diameter and cur-v vature than the outer end 98-. The two coogerating tube elements ,96 and 97 are a apted to fit over thebase 100, ofthe lamp bulb and include between their. edges the projecting pins 101 formed integral with the base of the lamp. 4 ,The'e'clge's 99 of the tube members 96' and 97 adjacent the pins inclined downwardly from the axial plane and thus not causing to an observer in front of the 90 and extending in a circular 101 are somewhat inwardly curved to form surfaces adapted to contact with the pins 101 and thus retain the shield elements from axial movement. on the lamp base. The portion of the tubes 96 and 97 adjacent the lamp bulb have a curvature less than the outer portions 98 so that when the nut 170 is rotated in such a direction as to force the'l1olding portion 65 upon the socket 66, the fingers 69 of the socket crowd the holding tubes 96 and 97 jamming the same into contact with the lamp base and thus unitin the whole into one solid unit from whicli possibility ofvibration and rotation dueto ar or movement of the support is entirely eliminated.

the

V filament above a plane Attention is directed to several important features of the invention.- In the use of'replacement reflectors as heretofore employed, the attachment has been usuall made at the flange at the outer edge oft e re lacement reflector and in such cases where tie old reflector was oil-center or distorted due to usage the replacement reflector also was moved oil the axial center thereby so moditying the reflected li ht rays as to make the reflector highly ineificient and cause undesirable glare. In applicants construction, the support and attachment is at the base of the re lacement reflector and at the axis of the reflector, and the clamping of the attaching nuts tends to draw the whole unit into proper relationship with the axis of the replacement reflector and thus produce the most effective distribution of light and the least distortion of the reflected rays. It is pointed out further that there is a close relationship between the lam) bulb shield 90 the filament of the lam bu b and the replacement reflector. The 'laments generally used are of V-formation lying in a plane, the apex of the V being toward the front of the lamp. In order to giv an undistorted reflection, the V plane is horizontal and the plane including the front edge 92 oi": the shield should also be horizontal in order to cut oil the rays of light emerging from the assing therethrough. Then also, especially in cases where a secondary reflector is used which is of the flat-lite type having vertical bar sections, it is essential tor eflicient illumination that the lane of the bars of the reflector be perpen ment so that in order to get the best results, the bulb shield, the filament, and the reflector should all have a certain predetermined relationship in their positions one to the other.

Attention is drawn also to the untility of the shield 90 in preventing glare under varied weather conditions especially in foggy weather where the light rays emerging from the lamp are subjected to multiple reflection from the various vapor particles, causing such diffusion of illumination as to make it exceedingly difficult for the operator of the car to visualize the objects in the path of movement of the vehicle. It has been found that by eliminating the rays of light which emerge in an upward direction from the headlamp that t the light beam is very largely eliminated so that much clearer vision is obtained to the operator than would be obtainable without the employment of the shield 90. The aperture bounded by 93, however, permits the emergence of those direct rays which illuminate the ground space directly in front of the car whereillamination is essential.

icular to the plane of the filais secondary reflection of the shield 90 and the band moaoes A further feature of the invention is the employment of the axial support washer 7 8 with the flexible fingers 76 which have been found exceedin 'ly useful in adjusting the replacement re ector to a distorted curvature of the primary reflector and to variation in sizes thereof. One method of attachment of the washer 73 is shown in Fig. 1,

but it is obvious that by removing the nut 72 and reversing the washer so that the fingers s read farwardly instead of inwardly, hat the unit could be readily adjusted either to another t pe. of primary rc- -flector having different imensions or to a variation in the distances between the primary and secondary reflectors. This ad- 'ustment is facilitated b means of the adjustment screw 53 whic shifts the whole contact connecting unit bodily inside the tube 15 and by tightening this screw the replacement reflector may be drawn rearwardly until the same islit snugly in place against the-primary reflector. Another 'as-, pect of the invention meriting attention is the combination of the shieldby means of the straps 94.- and 95 with the clamping shells 96 and 97, these shells being of a thick ness approaching that of the pins 10l. This construction permits rotation of the" base of the lamp so as to place, the filament in horizontal position and also in roper relationship with the re lacement re cctor where the reflector of the ar type is employed. This adjustment may be either in rotation or in axial movement, the construction permitting either adjustment, one as readily as the other;

Fig. 4 discloses a modification of the invention wherein a shield arrangement similar to that-disclosed in Fig. 1 is utilized with a lamp bulb adapted to be inserted in the ori inal reflector. This type of shield may e utilized either by the manufacturer of the lamp and supplied as part of the regular equipment, or the operator of the car may readily apply the same to the lamp bulb within the reflector. As illustrated, the clamps adapted to pass over the basefof the lamp as shown in Figure 1 are eliminated, only enough of the metal being retained to form clamping arms 110 conforming to the curvature of the lamp and having outturned tips 111 adapted to facilitate placement on the lamp bulb. In the utilization of this form of the invention, the type of lamp bulb is used which when attached to the original reflector of the headlamp by means of the slot 112 and base pin 113 places the plane of the lamp filament 114 "in a horizontal osition and with the filament thus fixetf the shield 115 may be positioned on the lamp bulb so that its base lies in a plane parallel to the plane of the filament.

In Fig. 5 a still further modification of and reflector.

the shield is shown in which the sector 124 sertion of the same in the socket of Fig. 1.

Various other modifications of the invention will become apparent to those skilled in the art and therefore it is desired to protect fully all such modifications as come within the spirit of the invention and as defined by the claims hereto appended.

Having thus described the invention, what is claimed is:

1. A replacement reflector unit positioned in a reflector of a lamp, comprising a reflector; a lamp bulb positioned in the reflector; a shield positioned in front of the lamp bulb; means for securing said reflector, bulb and shield together; and additional means for centering the replacement reflector within the primary lam reflector comprisin diverging resilient gers attached to the ase of the reflector and contacting at the free end of the fingers with the primary lamp reflector.

2. A replacement reflector unit comprising a reflector; a lamp bulb positioned in the reflector; a shield positioned in front of the reflector; means for; binding said shield, er, said means in-- bulb and reflector togeth eluding a socket member having a flexible wall positioned in the reflector base; and a member mounted on'the socket for bindin the socket wall with thelamp bulb, shiel 3. In a replacement reflector unit including a reflector a lamp bulb and a bulb shield; means or holding said shield, bulb and reflector together, said means com rising an externally threaded shell socket av- ,ing a flexible wall inserted in the base of the reflector and receiving the bases of the reflector and shield; and a nut in' threaded engagement with the" socket and movable in clamping relationship and flexible socket wall.

4. In a replacement reflector unit for headlights, a reflector, a. lamp bulb, a connector comprisinga socket having a flexible wall.

receiving the base of the lamp bulb and positioned in the base of the reflector, and means for forcing the Wall of the socket into holding relationship with the lamp bulb base and reflector.

5. In a replacement reflector for headlamps including a primary reflector, means for holding said replacement reflector in place within the primary reflector, said means including a tubular member secured to each reflector and a circular plate having flexible radial fingers fixed to. the replacement reflector'and. adapted to contact with the primary reflector. I

6. A replacement reflector unit comprising a reflector;'an electric lamp bulb having a base positioned within the reflector; a shield positioned in front of the lamp and having supporting members connected with the base of said lam and clamping means for, holding said shield supporting mem-, bers in engagement with the lamp base and supporting said reflector with respect thereto.

In testimony whereof,-weaflix our signatures.

SAMUEL F. ARBUCKLE. L CARL P. BROCKWAY.

with said reflector 

